FACILITY AND METHOD FOR PRODUCING VALUE AND SECURITY DOCUMENTS FROM PRE-MADE MATERIAL PIECES

Description

Field of the invention

[0001] The present invention relates to a system and a method for producing valuable and security documents from pre-cut pieces of material. The produced security documents can be, for example, identity cards or other identification cards (ID cards), or they can be bound as individualizing cards in a book-like identification document, such as a passport book. Furthermore, valuable documents can be, for example, credit cards or debit cards. Background of the invention

[0002] Identification documents, particularly identity documents such as identity cards, serve to verify a person's identity. Identity documents are issued by government authorities in the exercise of their sovereign duties, for example, to enable the document holder to cross the border into another country or to identify themselves to an official body or other persons. One such identity document is the German identity card, which is currently issued in the form of an ID card in ID-1 format according to ISO / IEC 7810 in the version valid on the priority date of the present application.

[0003] The ID card contains the individualizing (personalizing) data of the document holder, such as name, date and place of birth, nationality, a facial image, and the signature of the document holder, as well as a serial number identifying the document, the date of issue of the document, and information about the issuing authority and the type of document. It also contains the current place of residence and other biometric data of the holder (height, eye color). Furthermore, the ID card is equipped with various security features that allow a third party to verify the authenticity of the document, such as a guilloche pattern, a hologram displaying the holder's facial image and the machine-readable area of ​​the document containing personal and other data, and a cinematic object displaying, for example, the federal coat of arms.

[0004] The identity card can also be incorporated into a book-like security document, such as a passport book. In addition to the personal identification data on the document card, which in the case of a German passport has the ID-3 format according to ISO / IEC 7810 in the version valid on the priority date of this application, passport books contain additional book pages on which so-called visas from the countries the person is entering can be affixed. The document card, the passport book pages, and a cover are bound together using a stitching process.

[0005] The document card, for example an ID card, can typically be in the form of a plastic laminate with a laminated piece of film containing the required information, for example made of a polymer material. For the production of passport books, the document card is provided with a so-called passport flap, which protrudes laterally beyond the intended format of the document card and is stapled together with the passport book pages. DE 10 2008 031 654 A1 states that such document cards, which are made exclusively from polycarbonate layers, are not suitable for incorporation into a passport book. Therefore, it is common practice to produce document cards with a card body incorporating at least one layer made of a different plastic material that is suitable for binding into a passport book and allows the document card to be easily turned over in the passport book.This plastic layer is incorporated in such a way that it forms the flap with which the document card is bound into the passport book.

[0006] EP 2 452 904 A2 describes a device for transporting stacks of document or book blocks of security-relevant documents along a transport path to a plurality of binding stations provided for binding the stacks, preferably arranged in a row next to the transport path.

[0007] US 5,414,974 A describes a system for automated document handling. Documents printed by high-performance printers are fed into various containers. Each set of documents is assigned a sheet with a barcode, the reading of which controls the assignment to the containers.

[0008] EP0 358 066 describes the further processing and conveying of printed products at high speed. This takes place by organizing the printed products into clusters. A printed product cluster is a group of at least two individual printed products that are processed together in cluster streams over at least a partial route or sub-process. Such a cluster stream can be divided or reduced to a lower-order cluster stream (decreasing number of printed products per cluster). It is also possible to mix or link cluster streams. This makes it possible to create a fundamentally open-ended processing capacity at the desired points within an overall system. At the same time, the method enables increased flexibility through special buffer options, redundancy, etc. with relatively low material and cost expenditure.

[0009] EP 2 090 441 A1 describes a processing device having at least one tool for processing a respective printed product and a transport device with which the printed products are fed to the at least one tool. On their way to the processing device, the printed products are each provided with a detectable information feature, the data of which is detected by a reader and used to process the printed products. The data for processing the printed products are transmitted to a control device, which controls the at least one tool for processing the individual printed products based on the received data. Each printed product is processed based on the data of its information feature. The method is intended in particular for the trimming of sequentially produced books of different formats.

[0010] DE 601 02 372 T2 describes a system for personalizing a multi-page bound document, comprising: an input hopper constructed to receive a plurality of bound documents, a plurality of page-turning mechanisms arranged downstream of the input hopper, each page-turning mechanism including a device for turning pages of a document, and a plurality of personalization mechanisms arranged downstream of the input hopper, each personalization mechanism being capable of performing a personalization operation on one page of the document, the page-turning mechanisms and the personalization mechanisms for at least two of the personalization mechanisms being arranged such that a page-turning mechanism is located upstream of each of the two personalization mechanisms.

[0011] EP 0 364 370 A2 describes how, in the production of passports containing multiple sheets of paper and a data sheet coated with transparent plastic film, personal data such as the passport holder's name, place of birth, and date of birth are burned into the paper insert of the already plastic-coated data sheet using a laser beam. The passport can be bound into a book before the plastic-coated data sheet and additional paper data sheets are provided with data relating to the passport holder. Objects underlying the invention

[0012] The identification documents (security documents) described above are traditionally produced in production plants based on so-called island solutions, i.e., the individual production steps are carried out in only loosely linked plant sections. The required raw materials and resulting intermediate products are loaded and unloaded and transported manually in boxes from one plant station to the next, i.e., the documents are produced in batches. This approach is disadvantageous, for example, because the plant requires a lot of space and the plants are stationary. Furthermore, these plants are inflexible with regard to their suitability for producing different document types, since only one document type can be produced in a batch, resulting in long throughput times for the identification documents.Another problem is that the individual process steps require different capacities of the corresponding system components. This problem can be exacerbated by the failure of individual system modules, forcing document production to be interrupted and extending the batch processing time even further. The same applies if individual documents are produced incorrectly and therefore need to be reprinted.

[0013] Therefore, one object of the present invention is to create a production facility that requires little space and is also highly flexible in its use, allowing the production of various types of valuable and security documents. A dedicated production process should be executable in the production facility.

[0014] Furthermore, it has been found that the production of valuable and security documents requires a considerable amount of time, especially when they are produced at a central production facility. This is because different types of documents must be produced simultaneously in this case. Therefore, the present invention is based on the further object of creating a system for producing valuable and security documents and a method for producing them, which enable the rapid production of even different types of valuable and security documents.

[0015] In addition, the production of valuable and security documents should also be possible at low cost and with the lowest possible waste, as well as in compliance with the necessary occupational health and safety measures, particularly with regard to less intensively trained operating personnel working in a decentralised production facility.

[0016] A further very important object of the present invention is therefore to create a production plant and a production method with which the value and security documents can be produced with the shortest possible throughput time. Definitions of terms used in the present invention:

[0017] Where the term 'plant module' is used below, it is understood to mean a physical production unit with defined inputs and outputs that makes changes to the properties of the raw material pieces supplied to it.

[0018] Where the terms "individualized" and "individualizing" are used below, they refer to a property of a valuable or security document, such as a credit or ID card or passport, that allows the document to be assigned to a specific subject (person, animal, object). This property results from predefined security features of the valuable or security document. Where the terms "personalized" and "personalizing" are used below, they refer to the property of a valuable or security document that allows the document to be assigned to a person.

[0019] Where the term 'value and security document' or 'value or security document' is used below, this preferably refers to a document in the form of a flat, particularly preferably rectangular, carrier for individualized information to be displayed. A value or security card is understood to be both a rigid and a flexible object, i.e., an object that is not or only slightly bendable or twistable, as well as an object that is easily bendable. For example, the card can have one of the formats ID-1, ID-2, or ID-3 according to ISO / IEC 7810 in the version valid on the priority date of the present application.The valuable or security document can be, for example, an identity card, driver's license, access control card or other ID card, a check, bank, credit or cash payment card, customer card, health card, chip card, company ID, proof of authorization, membership card, ticket, gift or shopping voucher, or other card-shaped proof of authorization. The valuable or security document can be made of a material suitable for the purpose according to the invention, for example of a plastic (polymer), paper, cardboard, glass or other materials or mixtures of these materials, and optionally filled with reinforcing materials. The valuable or security document is produced by lamination from laminate layers, which, for example, consist of a material suitable for lamination.The valuable or security document can be formed from a polymer selected from a group comprising polycarbonate (PC), polyethylene terephthalate (PET), their derivatives, such as glycol-modified PET (PETG), polyethylene naphthalate (PEN), polyvinyl chloride (PVC), polyvinyl butyral (PVB), polymethyl methacrylate (PMMA), polyimide (PI), polyvinyl alcohol (PVA), polystyrene (PS), polyvinylphenol (PVP), polypropylene (PP), polyethylene (PE), thermoplastic elastomers (TPE), in particular thermoplastic polyurethane (TPU), acrylonitrile-butadiene-styrene copolymer (ABS) and their derivatives, polyamide (PA) and / or paper (cellulose) and / or cardboard and / or glass and / or metal and / or ceramic. Furthermore, the valuable or security document can also be made from several of these materials, in particular if the individual layers are formed from different materials. The value or security document is preferably made of PC or PC / TPU / PC.The polymers can be either filled or unfilled. In the latter case, they are preferably transparent or translucent. If the polymers are filled, they are opaque. The thickness of a document card is preferably 250 to 950 µm. Basic features of the invention and preferred embodiments:

[0020] According to a first aspect of the present invention, the above objects are achieved with a system defined in claim 1 for producing value documents, in particular credit cards, cash cards, and other value documents, particularly preferably value cards, and security documents, particularly preferably security cards, in particular identity cards and identification cards to be incorporated into book-shaped identification documents. The production system according to the invention serves to produce the value or security documents from pre-material pieces in at least two processing steps of a processing scheme.

[0021] If appropriate, at least one second transport unit, different from the at least one (first) transport unit mentioned in claim 1, further connects, according to the invention, all second system modules to third system modules, which are designed to carry out a third processing step subsequent to the processing scheme, if the production system has system modules for carrying out at least three processing steps and at least two transport units. This means that all system modules intended to carry out a processing step are approached by at least one transport unit, and that, furthermore, pre-material pieces are conveyed from these system modules to further system modules for carrying out a further processing step by means of at least one transport unit.

[0022] Furthermore, according to the invention, the at least one transport unit can also be controlled by the system control unit, so that the pre-material pieces can each be fed to one of several system modules designed to carry out a processing step. This means that the at least one transport unit is controlled by the system control device in such a way that a pre-material piece is fed to one of these system modules. The pre-material pieces can therefore be fed to these system modules alternatively.

[0023] According to a second aspect of the present invention, the above objects are also achieved by a method defined in claim 8 for producing valuable or security documents from pre-material pieces in at least two processing steps of a processing scheme. For this purpose, system modules designed to carry out the at least two processing steps are used, which are connected by at least one transport unit.

[0024] The feeding according to method step (ii) can, for example, depend on the availability of each of the system modules designed to carry out the method step to be performed. This method step (ii) also includes the system module being first selected before the transport unit is activated and the semi-finished material piece is then fed to the selected system module. Between (iv) and (v), the semi-finished material piece can be removed again from the system module in which it was processed, whereupon it is conveyed to another system module by means of the at least one transport unit according to (v) for the execution of further method steps of the processing scheme.

[0025] In a preferred embodiment of the present invention, changing at least one property of the pre-material pieces according to method step (iv) comprises printing the pre-material pieces and / or collating the pre-material pieces and / or laminating the pre-material pieces and / or edge-trimming the pre-material pieces and / or determining the quality of the laminated and edge-trimmed pre-material pieces and / or generating a hologram and / or applying the hologram to the pre-material pieces and / or trimming the pre-material pieces to size and / or attaching a tab to the pre-material pieces and / or laser engraving the pre-material pieces. Such method steps can be used to produce an identification card.To produce a book-shaped document in which the identification card, for example, is combined with other document components to form the book-shaped document, process steps are carried out which include, for example: bringing together cover sheets and endpapers and laminating the endpapers to the cover sheets, furthermore printing visa sheets with data and separating visa sheets from the printed visa sheets, furthermore gathering, stacking and fixing the laminated cover sheets, the visa sheets and an individualised document card to one another, combining the laminated cover sheets, visa sheets and individualised document card to form a book with a sewing process, trimming the book to the final format, laser perforating individual pages of the book and the final checking of the finished book-shaped document.The value or security documents are preferably produced in individual copies in the production plant according to the invention using the production method according to the invention.

[0026] According to a third aspect of the present invention, the above objects are also achieved by a method defined in claim 15 for producing a totality of several different value and security documents according to individual processing schemes by carrying out the method according to the invention.

[0027] In a preferred embodiment of the present invention, the system comprises at least first system modules designed to carry out a first processing step, second system modules designed to carry out a second processing step, and third system modules designed to carry out a third processing step, wherein all second system modules are connected to all first system modules by means of at least one first transport unit and all third system modules are connected to all second system modules by means of at least one second transport unit different from the at least one first transport unit.According to this embodiment, the at least one first transport unit is designed exclusively for transferring the pre-material pieces from the first system modules to the second system modules and the at least one second transport unit is designed exclusively for transferring the pre-material pieces from the second system modules to the third system modules.

[0028] According to this preferred embodiment, process step (iii) comprises feeding the pre-material piece to a first selected system module and process step (v) comprises the following further process steps: (v-1) Controlling at least one first transport unit (4100) assigned exclusively to the first system modules (3100) and second system modules (3200) by means of the system control unit (2000) for feeding the piece of preliminary material to a second selected system module (3200) designed to carry out a second processing step; (v-2) Feeding the raw material piece to the second selected system module (3200); (v-3) Carrying out the second processing step in the second selected system module (3200) by changing at least one property of the raw material piece; (v-4) Controlling at least one second transport unit (4200) exclusively assigned to the second system modules (3200) and third system modules (3300) by means of the system control unit (2000) for feeding the piece of preliminary material to a third selected system module (3300) designed to carry out a third processing step; (v-5) Feeding the raw material piece to the third selected system module (3300); (v-6) Carrying out the third processing step in the third selected system module (3300) by changing at least one property of the raw material piece.

[0029] This may be followed by further process steps (ii), (iii), (iv) in accordance with process step (v).

[0030] According to a further embodiment of the present invention, the system modules and transport units are arranged relative to one another in such a way that system modules, each designed to carry out a processing step, and the transport units form a linear chain so that the pre-material pieces can pass through them one after the other.

[0031] The raw material pieces used in the process according to the invention, produced in the individual processing steps and then further processed in subsequent processing steps, are, for example, the following materials in a typical production process according to the invention: Polymer film pieces intended for printing with reproductions of individualising data and subsequent lamination; polymer film pieces intended for lamination without being printed, as well as security threads, security elements (patches) and other laminatable film pieces; a polymer film piece printed with reproductions of individualising data in a printing device; a stack produced by gathering printed and unprinted film pieces, security threads, security patches and other film pieces, which stack is to be fed to a laminating device; a laminate piece produced by a laminating process; a laminate piece trimmed in an edge trimming process; a hologram film; a hologram film produced in a hologram production device, exposed to and fixed with a hologram; a laminate piece provided with the hologram;a laminate piece provided with the hologram and trimmed to a desired format in a format-trimming device; a laminate piece provided with a flap, this laminate piece being intended for binding into a book-shaped valuable or security document; and a laminate piece provided with laser-engraved reproductions of data.

[0032] The above-listed raw material pieces are intended for the production of an identification card. Similarly, suitable raw material pieces can also be used to produce a book-shaped document, such as cover sheets, endpapers, and visa sheets. In this case, the identification card can be combined with other such document components to form the book-shaped document.

[0033] According to the production method according to the invention, according to process step (i), the pre-material pieces, i.e., corresponding precursors of the value or security documents, are first provided, for example, pieces of film to be laminated, including an inlay film piece, laser-engravable film pieces, and optionally a film piece bearing an RFID circuit, a security thread, a security patch, and the like. Preferably, five to nine film pieces are collected. To produce the documents, the individual processing steps of the processing scheme for producing the value and security documents are carried out.To carry out a single one of several processing steps, the following method steps are then carried out: According to method step (ii), at least one transport unit is controlled by the system control unit so that a piece of raw material is conveyed to one of several system modules which are designed to carry out a processing step on the piece of raw material. One criterion for selecting the system module is, for example, the availability of the system modules for this processing step. The available system module is selected. If several parallel system modules are available to carry out a specific processing step, any one is selected. According to method step (iii), the piece of raw material is then fed to the selected system module. According to method step (iv), the piece of raw material is processed in the selected system module. For this purpose, a property of the piece of raw material is changed.For example, the pre-material piece is a piece of polymer film that is printed with individualizing, in particular personalized, data using a printing device, or the pre-material piece is a piece of polymer laminate coated with a hologram film that is trimmed to the desired format using a format trimming device (format cutting). To perform further processing steps on the pre-material piece, the aforementioned process steps (ii), (iii), and (iv) are performed again.

[0034] The system modules of the production system according to the invention are logically linked according to the intended processing scheme in the sequence of processing steps specified by this scheme. According to the invention, not only one system module is necessarily provided for each individual processing step; rather, several system modules can be provided. At least two system modules are available to carry out at least one of the processing steps. If several system modules are provided to carry out a processing step, one of these system modules is selected for processing a piece of preliminary material. The at least one transport unit is designed to connect the system modules of different processing steps to one another. This results in a network in which the system modules represent the nodes and the transport units represent the node connections.According to the invention, the individual system modules are therefore not rigidly linked to one another. This is achieved by a flexible transport system. The raw material pieces are automatically delivered to the system modules via the transport units, controlled by the system control unit.

[0035] The inventive flexible linking of the system modules for different processing steps in the processing scheme makes it possible for the first time to optimize the utilization of the system modules caused by different cycle times in the processing steps. By maintaining several redundant system modules for a processing step that requires a long cycle time, a piece of raw material is transported from a previous processing step with a shorter cycle time to a system module that is not currently in use and processed there. A subsequent piece of raw material can then be guided to another available system module to carry out this processing step. This significantly increases the availability of the entire production system. This also applies in the event of a system module failing, for example due to a malfunction.In contrast to rigidly linked plant modules, where the entire plant fails, for example, if one of the plant modules fails, the invention redirects production via redundant plant modules so that the plant can continue to operate.

[0036] The present invention solves the problem that several different product variants of a value or security document can only be produced with conventional production systems after conversion, resulting in considerable time delays and thus long production times. This is because different document variants are typically produced batch by batch in the same production system, with the system being converted after the production of a batch of a first document variant in order to set it up for the production of a second document variant. By providing several system modules according to the invention, each of which is designed to carry out one of several different processing step variants, the individual pieces of raw material can be guided as intended to the system modules provided for this purpose, which are designed to carry out the respective processing step variant.For example, several types of laminating sheets (e.g. in different formats and / or with different embossed structures) can be stored in a laminating module.

[0037] Furthermore, the present invention can also solve the problem of a system module failing, for example, due to a malfunction or other event (e.g., due maintenance, loading with raw material). In conventional production systems, this leads to the entire production being interrupted. By maintaining redundant system modules for each processing step, or at least for those processing steps that are prone to failure, the material flow can be directed via the system modules of the corresponding processing step that are still in operation, thus avoiding the need to interrupt production.

[0038] The system according to the invention can also provide for the application of the same processing scheme for a group of different (individual) valuable or security documents. Such valuable or security documents can, for example, only differ in terms of personalization. For example, an individual processing scheme can be provided for one group of passports; a different individual processing scheme is then provided for another group of passports. Within the groups themselves, however, the respective individual processing schemes for the individual passports are then the same.

[0039] The decision as to which of several system modules of a processing step the raw material piece should be transported to is made by the system control unit depending on the availability of each of the system modules configured to carry out the processing step to be performed. This decision is sent as a control command to the at least one transport unit that transports the raw material piece to the selected system module. The availability criterion is determined, among other things, by the utilization, the operating status of the respective system modules of the processing step to be carried out (for example, depending on the occurrence of a malfunction, pending maintenance of the system module and / or a temporarily changed processing time in the system module) and the variants of the processing step that can be carried out in the individual system modules.

[0040] The system control unit is formed by an electronic processing unit and preferably has a unit for storing data. This is preferably a conventional process computer. The system control unit can be a programmable control unit.

[0041] The plant control unit controls all transport units (and optionally the plant modules) in the production plant according to the invention and is designed to transmit data to all transport units (and plant modules) and to acquire data from all transport units (and plant modules). The plant control unit can be formed by a central processing unit that communicates directly with all transport units (and plant modules), as in a conventional production control system. Alternatively, the plant control unit can also be formed by a hierarchical system in which subordinate processing units are assigned to a higher-level processing unit, which in turn each communicates with the transport units (and plant modules) assigned to them. To this end, the subordinate processing units control the transport units (and plant modules), transmit data to them, and acquire data from them.The subordinate processing units can each be assigned to groups of transport units (and system modules), for example, individual production units (see below) in which several transport units and system modules are combined. The higher-level processing unit controls the subordinate processing units and is designed to transmit data to them and collect data from them. For example, it is advantageous if the higher-level processing unit transmits data about raw material pieces that are fed to a production unit and that have been processed in these production units to the respective subordinate processing unit or receives data from the subordinate processing unit, while the results of intermediate steps during processing within the production units are not communicated to the higher-level processing unit but only to the subordinate processing units.

[0042] Communication lines are used to transmit data and control commands from the system control unit to the system modules and transport units, and from these to the system control unit. In particular, a LAN, for example, based on a fiber optic network, can be provided for this purpose. Instead of a LAN, a wireless network (WLAN) can also be installed.

[0043] The system modules are preferably the following production modules, which are designed in a conventional manner: At least one of the system modules can be formed by a printing device or by a feeding device for gathering pieces of raw material or by a laminating device or an edge trimming device or a device for determining the quality of the pieces of raw material produced during lamination and edge trimming in the form of laminate pieces or by a hologram generating device or by a hologram applying device or by a format trimming device or by a device for attaching a tab to the pieces of raw material or by a laser engraving device or by a device for recording the quality of the finished valuable or security document.These processing steps can be used to produce a document card, such as an identity card or an identification card intended for inclusion in a book-like document, such as a passport.In a corresponding manner, system modules for producing a book-shaped document in which the identification card, for example, is combined with other document components to form the book-shaped document can be used, in particular the following system modules: a laminating device for joining a cover with an endpaper, printing devices for printing visa sheets, cutting devices for separating visa sheets from printed visa sheets, a collating machine with a manipulator and a collecting station for a laminated cover, visa sheets and an identification card, a sewing device for joining stacked components of the book-shaped document, a folding device for folding the book, a trimming device for trimming the book to the final format and a quality assurance device for the final inspection of the book-shaped document.

[0044] The transport units can be designed in the form of continuously operating transport devices, in particular translationally operating transport devices, such as conveyor belts on which the pre-material pieces rest, translationally movable holding elements for the pre-material pieces, such as mechanical, pneumatic, magnetic or adhesive grippers, including vacuum handling devices which transport the pre-material pieces from a first system module to a second system module, or other translationally movable holding elements.The transport units can preferably be characterized in that a transport unit connects at least one first system module, which is provided for carrying out a first processing step, with at least one second system module, which is provided for carrying out a second processing step subsequent to the processing scheme, and that preferably a further transport unit is additionally provided and used, which serves to link the first or second system modules with other system modules for carrying out further processing steps. Alternatively, stationary or movable robots can also be used. These transport devices can, for example, be equipped with vacuum handling devices and / or grippers. The robots can, for example, be formed by lifting and swiveling robots, for example SCARA robots (Selective Compliance Assembly Robot Arm), or a fast picker or a gantry crane.

[0045] To implement a flexible connection between the system modules and the transport units arranged spatially and functionally between them, the interfaces between the system modules and transport units must be defined, both in terms of the equipment (hardware) and the software. To ensure the hardware-related adaptation of the system modules and transport units to one another, the transfer points between the two system components must be adapted. A standardized transfer interface with identical inputs and outputs is particularly advantageous for this purpose. This allows the system modules and transport units to be plugged together in terms of hardware, whereby the system modules can also be combined in any order.In particular, it can advantageously be provided that the raw material pieces are transported at the same level in both system components. With regard to the software adaptation, suitable algorithms for the transmission of data and control commands between the system modules and transport units on the one hand and the system control unit on the other hand must be provided, for example, the TCP / IP protocol. With the help of this software adaptation, a clear control of the material flow between the system modules and the transport units can be achieved.

[0046] Therefore, according to a preferred embodiment of the present invention, the system modules each have devices for transferring the pre-material pieces to and from the at least one transport unit, wherein the levels of the transfer devices are designed to be at the same height. To adjust the height levels, a combination lift, for example, can be used, which raises / lowers the pre-material pieces to the level of the subsequent system module or the subsequent transport unit.

[0047] Due to the level design of the transfer devices, the raw material pieces can be transferred easily between the system modules and the transport units because there is no height difference to overcome.

[0048] The system modules provided for the production of a valuable or security document using the method according to the invention, each of which is designed to carry out one of the processing steps in the underlying processing scheme for this valuable or security document and is provided in the required number, do not have to be arranged in a specific relationship to one another. The only essential requirement is that the system modules are arranged in a network-like structure together with transport units connecting the system modules. The system modules can represent network nodes, and the transport units can represent the connections between the nodes. Accordingly, one or more such connections can lead to or originate from a node.Preferably, one or more nodes, each corresponding to a system module intended for executing a processing step, are connected to one or more other nodes, each corresponding to a system module intended for executing a different processing step, via one or more connections, wherein each connection represents a transport unit. It is of course advantageous for several system modules designed to execute the same processing step, as well as system modules designed to execute successive processing steps, to be arranged in spatial proximity to one another so that the transport times between the system modules of successive processing steps are minimized as much as possible.

[0049] The system modules and transport units, as well as other components such as supply and communication lines, can be housed in a container or a container-like structure. In particular, the system modules designed to perform a specific processing step (parallel system modules: redundant identical system modules and, if appropriate, system modules for performing a processing step in multiple variants) can be assembled in a cluster, for example, in a container. Likewise (additionally or alternatively), system modules designed to perform successive processing steps can be assembled in a cluster, for example, in a container. Several containers with module clusters can then be assembled in a suitable manner.The containers or container-like structures are preferably designed in the form of standardized large-capacity containers, such as ISO containers, but possibly without the side walls, floor wall, and ceiling wall, but rather in the form of supporting structures, for example, a truss construction, with the appropriate dimensions. Production units (cubes) designed in this way are easily transportable and therefore mobile, and can be assembled in standardized dimensions, allowing them to be combined as desired.Since the system modules intended for the production of valuable and security documents, for example, a laminating device for bonding polymer film pieces to form a polymer laminate piece, a format trimming device for cutting the laminate piece to a desired format, or other system modules, as well as the transport units and other structural units (components), are permanently installed within the respective containerized production units, the production units and their components can be easily transported from a production site to an installation site, where they can be assembled and installed. The system modules, transport units, and other structural units are preferably located in the respective production units in a spatial arrangement relative to one another that they require for the operation of the production units for the production of valuable and security documents.In particular, system modules for carrying out successive processing steps can be arranged in spatial proximity to one another.

[0050] As explained above, the transport units (and plant modules) in the clusters can be controlled by a hierarchically organized plant control unit with a higher-level control unit and several control units subordinate to this control unit, whereby the transport units (and plant modules) of a cluster (in a manufacturing unit) are controlled by a subordinate control unit.

[0051] Instead of installing the system modules, transport units, and other components in containers or container-like structures, these components can also be installed individually without being installed in a container or container-like structure. Of course, it is also possible for some components to be installed in containers or container-like structures, while other components are installed freestanding without being installed in a container or container-like structure.

[0052] The system control unit is designed to control the system modules and the at least one transport unit between the system modules of successive processing steps. This allows the raw material pieces to be transported in an intelligent logistical material flow to the available system modules, including those designed for the respective processing step variant. The system control unit thus controls the path the raw material pieces take through the production system. To do this, the system control unit delivers the necessary control commands to the at least one transport unit and, if necessary, to the system modules. To control the transport units and system modules, the system control unit accesses processing schemes ("recipes") underlying the production of valuable and security documents, which are stored in a database.These processing schemes list the processing steps for each valuable or security document to be produced in the order in which they are processed. If there are different types of valuable or security documents, for example, with different formats, security features, and / or other properties of the valuable or security documents, the individual processing schemes are also based on different basic processing schemes, each of which applies to a group of similar documents. The processing schemes can contain processing steps that are included in all processing schemes and processing steps that are only included in some processing schemes and are therefore optional.

[0053] The transport units, like the plant modules, can be mapped in the plant control unit as production modules to be controlled. As in the case of conventional rigidly linked plant systems, in which the transfer of the raw material pieces from one plant module to a subsequent plant module is reported to a control system as quasi-instantaneous, control concepts of conventional plant systems can also be used for the production plant according to the invention insofar as the transport units, as stated above, are simulated in the plant control module as production modules just like the plant modules. In this case, too, the production modules communicate the module transitions from the output of a preceding module, for example, a transport unit, to the input of a succeeding module, in this case, a plant module, to the plant control unit.When communicating data about the properties of the raw material piece from the system control unit, the condition of the raw material piece can be transmitted as its property from the system control unit to the transport unit, to which of several system modules the raw material piece is to be fed. Furthermore, the properties of the raw material piece, in particular regarding the process variant to be selected, can be transmitted to the transport unit so that a decision can be made about which system module following the transport unit the raw material piece should be fed to.

[0054] Furthermore, it can preferably be provided that the system control unit also transmits the data associated with a specific piece of raw material, for example, the data required to identify this piece of raw material, perhaps as being assigned to a specific person, to the at least one transport unit, so that secure product tracking is enabled and, if necessary, appropriate modifications to the processing step in this system module can be made and, if necessary, individualizing data can be applied to the piece of raw material and / or within the piece of raw material. This identification can be carried out using the serial number of the valuable or security document to be produced and / or, in the case of documents containing a chip, using a chip identification number.This data can also be used to control a system module to apply an individualizing security feature to and / or into the piece of raw material. For example, reproductions of this data can be printed onto a piece of polymer film using a printing device, engraved into a piece of laminate using a laser engraving device, and / or exposed and fixed into a hologram film using a hologram generation device.

[0055] Furthermore, it can also be provided that the arrival of a specific piece of raw material at a system module, the completion of a piece of raw material in a system module, and the quality of the changes in the properties of the raw material step caused by the processing step in a system module are transmitted to the system control unit. Therefore, it can also be provided that the system control unit also controls the system modules and issues control commands to them, for example, when the start of processing of an incoming piece of raw material at a system module is to be triggered.Furthermore, when the completion of a processing step in a system module is reported, the data identifying the raw material piece, the time of the event (completion), data on the type and extent of the processing step performed, and, if applicable, other data, such as quality data (quality status), can be transmitted to the system control unit. For example, when the raw material piece arrives at a system module, an acknowledgment of arrival is transmitted to the system control unit, and in the case of completion, an acknowledgment of completion (status feedback) is transmitted. The transmitted status data, including other parameters, are logged in the system control unit.By transmitting the arrival of the raw material piece at a system module and the completion of the processing step in the system module, the system control unit is able to coordinate the scheduling of the processing steps for all raw material pieces to be processed in the production system. This also applies to the corresponding status data of the raw material pieces regarding their arrival at a transport unit and their departure from the transport unit. In this way, the location at which a specific raw material piece is located in the production system can be recorded. The status data of the raw material pieces in the system modules can be used to determine their availability based on the respective processing times.By recording the quality of the changes in the properties of a piece of raw material caused by a processing step in a system module, the further material flow in the system takes into account whether the processed piece of raw material was successfully processed in the processing step or whether it has to be processed again or removed from the production process as scrap.

[0056] Apart from transmitting individualizing data to the system modules, the system control unit preferably does not control the system modules. The system modules are therefore preferably designed to carry out the processing steps to be performed therein without external intervention, unless they require document-specific data to execute the processing steps. As soon as a piece of raw material has reached a system module, the selected system module preferably takes over the piece of raw material and automatically carries out the processing step that can be carried out there. Only when the system module is left is the further decision regarding the continuation of processing of the piece of raw material in other system modules taken over by the system control unit.For this purpose, the system control unit controls the transport unit that receives this piece of raw material so that it can be transported to the next available system module that is designed to carry out the next processing step in a system module.

[0057] In a preferred development of the present invention, at least two system modules designed to carry out one of the at least two processing steps are provided in the system according to the invention, each of which is designed to carry out a processing step variant for producing one of several variants of the value or security documents. Thus, the method according to this development of the invention can further comprise that the at least one transport unit is controlled by the system control unit such that the pre-material pieces are fed to one of the system modules designed to carry out this processing step variant depending on the execution of a processing step variant to be selected for producing one of several variants of the value or security documents.

[0058] For example, according to this development of the present invention, to carry out the processing step of gathering pre-material pieces to form a stack of polymer film pieces and other laminate components, different polymer film pieces can be integrated into the stack. In particular, stacks can be formed with different numbers and / or different formats of polymer film pieces and / or with different film types, for example made of different materials, for example polycarbonate, polyvinyl chloride, polyethylene terephthalate or combinations of these materials or with still other materials. Furthermore, the variant can additionally be provided that one film stack to be laminated should contain a film layer with an integrated RFID circuit with RFID chip and RFID antenna, and another film stack should contain no such film layer.The same applies to the integration of additional laminate components, such as a security thread or a patch to be laminated on or in. Furthermore, to carry out the processing step of laminating the film stacks, different system modules can be provided for different stack formats and / or different laminating processing conditions, for example, depending on the type of material to be laminated with regard to the laminating temperature, and / or laminating sheets with different embossed structures. Furthermore, to carry out the processing step of edge trimming the finished laminate piece, multiple system modules can be provided for different formats of the document to be produced.Furthermore, to carry out the processing steps of generating a hologram and applying the hologram to the laminate piece, multiple system modules can be provided for different geometries / shapes of the hologram film to be applied and / or for different sizes of the hologram film. Furthermore, to carry out the processing step of format trimming after applying a hologram film to the laminate piece, multiple system modules for different formats can be provided.

[0059] In a further preferred embodiment of the present invention, the production system can also contain system modules with which a processing step can be carried out that is merely optional in the processing scheme, i.e., is only to be carried out for a specific group of documents to be produced. The system control unit retrieves the processing schemes stored for the documents to be produced and accordingly determines which processing steps are to be carried out and thus which system modules are to be accessed.

[0060] For example, the system according to the invention can be provided with system modules designed to attach a tab to a laminate piece. Such a processing step is only carried out if the document to be produced is an ID card that is to be bound into a book-like document, such as a passport. In other cases, such a tab is not required, so it is not attached to the laminate pieces. In this case, this processing step is not carried out, so that the system modules provided for this purpose are not involved in the processing of the corresponding raw material pieces, for example, they are not approached.According to a further example of this preferred development of the present invention, system modules can also be provided with which a groove is introduced, for example, milled, into the laminate piece in order to fit a contact chip module (chip implant) into it. For documents to be produced that do not have such a contact chip, this optional processing step is not required, so that the system modules provided for this purpose are not involved in the processing of the corresponding pre-material pieces, for example, they are not approached.

[0061] According to a further preferred development of the present invention, the system control unit is designed to detect the identity of a piece of pre-material located in a system module or a transport unit and to control the feeding of this piece of pre-material to a system module depending on the identity of this piece of pre-material. To this end, the method according to the invention further comprises detecting the identity of a piece of pre-material located in a system module or a transport unit with the system control unit and controlling the feeding of this piece of pre-material to a system module depending on the identity of this piece of pre-material.

[0062] By detecting the identity of a piece of raw material, for example, by reading individualizing data already printed on or into the piece of raw material or by reading individualizing data from a chip, the identity of the raw material can be detected and compared with data stored in a database of the system control unit. Processing schemes for the document to be produced can also be stored in a database of the system control unit, so that by detecting the identity of the raw material, it can be determined which processing scheme to apply and, consequently, which further processing step to perform following a previous processing step.If necessary, data must be transferred to the executing system module to carry out the processing step, which, for example, is to be printed on the raw material piece, engraved into it or exposed into a hologram film.

[0063] According to a further preferred development of the present invention, the system control unit is designed to record and process data on the quality according to at least one quality criterion of a piece of preliminary material that has been processed in a system module designed to carry out a processing step that has been carried out, and to control the at least one transport unit for feeding this piece of preliminary material to a system module that is designed to carry out a subsequent processing step, depending on the determined quality according to this quality criterion.Accordingly, the method according to the invention further comprises the acquisition and processing of data on the quality according to at least one quality criterion of a piece of preliminary material that has been processed in a system module designed to carry out a processing step carried out, by the system control unit and the control of the at least one transport unit for feeding this piece of preliminary material to a system module designed to carry out a subsequent processing step, depending on the result of the processing of the quality criterion.

[0064] By recording and processing data on at least one quality criterion of a piece of raw material, for example the quality of a piece of raw material trimmed to a specified format, it can be ensured that the piece of raw material produced in this processing step meets the quality requirements and can therefore be subjected to subsequent processing steps in the processing scheme. In this case, the piece of raw material is further processed according to the method according to the invention. If, however, the quality of the processed piece of raw material does not meet the specified quality criteria, this piece can be considered a reject and ejected from the ongoing processing scheme. In this case, the production process for this valuable or security document must be restarted.This decision only affects the production of all subsequent valuable or security documents insofar as the allocation of valuable and security documents in production to the system modules is now carried out without taking this piece of material into account due to the failure of the rejected piece of material. Any previously manufactured preliminary products intended for the rejected piece, such as a hologram film with a hologram, can then be retained and used for the valuable or security document to be produced in the newly initiated production process. For example, such a preliminary product can be temporarily stored in a parking station. Suitable sensors, such as mechanical, electrical, or optical sensors, are used to record quality data according to the quality criteria.The latter can be created, for example, by camera systems with an image analysis system (vision system). To process the obtained quality data, it is compared with reference data stored in a database, for example, in the system control unit. If a significant deviation occurs, for example, if a specified tolerance range is exceeded, the inspected raw material piece is considered a reject.

[0065] According to a further preferred development of the present invention, the system control unit is further designed to detect and process data on the operating state (status) of at least one of a plurality of system modules designed to carry out a processing step and to control the at least one transport unit for feeding the pre-material pieces to the system modules designed to carry out this processing step as a function of the determined operating state.Accordingly, the method according to the invention further comprises the acquisition and processing of data on the operating state of at least one of a plurality of system modules designed to carry out a (specific) processing step by the system control unit and controlling the at least one transport unit for feeding the pre-material pieces to the system modules designed to carry out this processing step as a function of the determined operating state.

[0066] By recording data on the operating status of at least one of several system modules designed to perform a specific processing step and evaluating this data by the system control unit, the availability of the system modules for this processing step can be determined. If it becomes apparent that a system module requires maintenance and must be temporarily shut down for this purpose, or that a system module needs to be loaded with additional pre-products, for example, a hologram generation device with unexposed hologram film, this is registered by the system control unit and taken into account for the distribution of the pre-material pieces to system modules designed to perform the same processing step as the shut-down system module.If several redundant system modules are available for this processing step, the production process can be continued at a capacity at least close to that prior to the shutdown. Sensors and time recording devices are installed in the system module to record data on its operating status. These devices indicate any module malfunctions and / or upcoming maintenance and / or required precursor replenishment. To process the status data in the system control unit, the recorded data is compared with reference data stored in a database, e.g., the system control unit. In the event of a significant deviation, e.g., when a specified tolerance range is exceeded, the relevant system module is shut down.

[0067] The following figures serve to further explain the invention, but they merely represent illustrative examples of specific embodiments and do not limit the scope of the invention. They show in detail: Fig. 1 shows a schematic representation of a valuable or security document in cross-section; Fig. 2 shows a representation of the processing steps in an exemplary sequence for a production method according to the invention (processing scheme) using the example of the production of an identification card; Fig. 3 shows a schematic representation of a production plant according to the invention.

[0068] In the figures, identical reference symbols designate identical elements and / or elements with the same function. The figures do not always depict the objects to scale. Furthermore, the size relationships of individual elements to others within a figure or between figures are not always depicted to scale.

[0069] In Fig. 1 A value or security document 100 according to the present invention is shown. In the following description of the figures, an identification card is used as an example as a value or security document or another document card, for example, for inclusion in a book-shaped value or security document. In principle, however, other value or security documents, including book-shaped value or security documents, are also meant in all cases.

[0070] The ID card 100 is formed by a laminate of several polymer film pieces, for example, polycarbonate films. The illustration shows the film pieces delimited by boundary lines for illustrative purposes. However, these are no longer visible after lamination. The ID card is formed at the very top by a first transparent polymer cover layer 110, for example, made of polycarbonate; below this, a layer of an individualized film piece 120, also made of polycarbonate, for example; below this, a layer composite of a polymer layer stack piece 130; and at the very bottom, a second transparent polymer cover layer 140, also made of polycarbonate, for example.The layer composite is formed by a central RFID layer based on an opaque polymer carrier layer 131, for example made of polycarbonate, with an RFID circuit comprising an RFID chip 135 and RFID antenna (not shown) on the carrier layer, a compensating layer 132, for example made of polycarbonate, which accommodates the RFID chip in a recess, and an opaque cover layer 133, for example also made of polycarbonate, underneath. A hologram (not shown) is preferably located under the first polymer cover layer. The identification card, for example, has the ID-3 format according to ISO / IEC 7810 in the version applicable on the priority date of the present application if the card is to be bound into a passport (book-shaped document). Attached to the side of the card material, protruding from the card material, is a document card flap 150, which consists, for example, of a textile material that is fusible or is interspersed with a fusible material.This flap is bonded to the card material by hot-melt welding. If the card is intended for the production of an identity card, it will, for example, be in the ID-1 format according to ISO / IEC in the version applicable on the priority date of this application. In this case, no document card flap is attached.

[0071] An exemplary sequence of processing steps of a production method according to the invention, shown as an example for the production of an identity card 100, is shown in Fig. 2stated: For the production of one of the identification cards 100 or of document cards 100 that can be incorporated into a book-shaped value or security document, for example a passport, polymer film pieces are first provided in a first processing step, which are preferably formatted for the production of single-use cards. If necessary, in a mixed production of several card formats, film pieces can also be used, for example, which correspond to single-use in ID-3 format and double-use in ID-1 format. The film pieces are typically made of polycarbonate, polyethylene terephthalate or polyvinyl chloride or of combinations of these polymers and optionally also with other polymers. One of the polymer film pieces, for example the polymer end layer 110, is preferably made of polycarbonate suitable for laser engraving.The film pieces can be provided from a magazine in which the film pieces are stored, for example, stacked. For example, a removable magazine can also be used for this purpose, containing film pieces of different types, for example, made of different materials and / or in different formats, and from which the film pieces are removed as needed. The printed polymer film piece ultimately forms the layer of the individualized film piece 120 in the card. The polymer of this layer is preferably opaque.

[0072] In a second processing step, the polymer film pieces 120 are preferably printed with reproductions of individualizing data. The system module used for this purpose can be a printing device. Preferably, an inkjet printing process or any other digital printing process is used, with which the preferably individualizing data can be easily applied to the film piece. Therefore, the printing device can preferably be an inkjet printer.

[0073] In a third processing step, additional unprinted polymer film pieces 131, 132, 133, 140 and, if appropriate, other laminate components to be laminated are provided. The polymer film pieces, like the printed polymer film pieces 120, can be made from the polymers mentioned therein and have the formats specified therein. One of the polymer film pieces, namely the polymer film piece 131, can be formed, for example, by an RFID circuit layer with an RFID chip 135. Further laminate components can be a security thread, a security patch, and the like. The polymer film pieces 132, 133 and the RFID circuit layer, which form the polymer layer stack piece 130 in the finished card 100, are preferably opaque. The polymer film pieces, which form the second polymer end layer 140, are transparent.The polymer film pieces and the other laminate components to be laminated can be removed from magazines in which they are stored in stacks. These magazines can be interchangeable magazines containing film pieces and other laminate components of different types, for example, made of different materials and / or in different formats, and from which the film pieces and other laminate components are removed as needed.

[0074] In a fourth processing step, the polymer end layer 110, the printed polymer film piece 120, the additional polymer film pieces 131, 132, 133, 140, and any additional laminate components are assembled into a film stack and, if necessary, releasably secured to one another so that their position relative to one another cannot change. For this purpose, a feeder device for gathering these pre-material pieces is used as a system module. If laminates with different formats are to be produced, different feeder devices can be used that are adapted to these different formats.

[0075] In a fifth processing step, the film stack is then laminated in a laminating device as a system module for joining the polymer film pieces 110, 120, 131, 132, 133, 140 and other laminate components to form a polymer laminate piece. In this module, these laminate components are welded (laminated) into a single unit under the influence of pressure and heat, thus creating a laminate piece. The laminating device preferably includes a first station in which the film stack is enclosed on both sides by laminating sheets, a central laminating station in which the stack of film stack and laminating sheets is guided between press dies, and a third station in which the laminating sheets are removed from the finished laminate piece.The central station is preferably formed by a first device in which the package of film stack and laminating sheets is heated and pressurized in a first section (hot pressing), a second device in which the package is further heated in a second section (hot pressing), and a third device in which the package is cooled and pressurized in a third section (cold pressing). The laminating sheets associated with the card 100 to be produced are kept ready in a station and added to the film stack.If different materials are to be laminated together, so that different laminating conditions (temperature, pressure) have to be set, and / or if laminate pieces with different formats are to be produced and / or if different embossed patterns are to be embossed into the laminate pieces during lamination, so that laminating sheets with different formats and / or different embossed structures have to be used, various types of laminating devices can be used.

[0076] In a sixth processing step, the finished laminate piece is then edge-trimmed in an edge-trimming device that serves as a system module. Several different system modules can also be available for this purpose to enable different edge-trimming formats.

[0077] In a seventh processing step, the trimmed laminate piece is then fed to a quality assurance device, which also forms a system module. This system module checks the results of the lamination process and the edge trimming process. Camera systems, for example, are used for this purpose.

[0078] In parallel, in an eighth processing step, a hologram film is provided as a system module in a hologram generation device, for example, as a roll from a roll-off device. In a ninth processing step, it is exposed and fixed in this system module, forming a hologram in the hologram film. If multiple card formats are to be produced, several such system modules can be maintained, allowing holograms of different formats to be generated.

[0079] A section of the hologram film containing the hologram is then applied, for example, glued, to the trimmed laminate piece in a tenth processing step. A hologram application device serves as a system module for this purpose. In this system module, for example, an adhesive can first be applied to the trimmed laminate piece and then the hologram film section can be glued to the laminate piece. Since the hologram film typically has a protective film on the side to be applied and a carrier film on the opposite side, the hologram application device is designed to peel the protective film off the section before applying the section to the trimmed laminate piece. Likewise, this system module is therefore also designed to peel the carrier film off the applied section after application.Several different types of hologram application devices can be provided, which differ, for example, in terms of the formats of the holograms to be applied.

[0080] The laminate piece coated with the hologram section is then trimmed to the desired final format in an eleventh processing step. For example, if the laminate piece is a double-sided piece, the two panels are separated from the laminate piece. The system module used for this is a format trimming device, which can be a punching device, for example. Alternatively, it can also be a laser cutting device. These devices can also be available in several variants to produce the different formats.

[0081] After trimming the laminate piece to the desired final format, a document card flap 150 can be attached to the laminate piece in a twelfth processing step. A device for attaching the flap to the laminate piece is used for this purpose. This device is designed to connect the flap to the laminate piece, for example, by hot-melt welding, so that the device is equipped, for example, with hot-press stamps for partially melting the materials of the laminate piece and the flap. Alternatively or additionally, this device can also have an ultrasonic welding unit. The system modules provided for this purpose can differ with regard to the format of the card to be produced. This process step is carried out only optionally, and only if the document card 100 to be produced is to be incorporated into a book-shaped valuable or security document.Otherwise, this process step can be omitted. In the latter case, the trimmed laminate pieces obtained in the eleventh processing step are transported directly to a system module where the thirteenth processing step is performed.

[0082] In the thirteenth processing step, the trimmed laminate piece, which may be provided with the document card flap 150, is provided with further reproductions of, in particular, individualizing data by providing a laser-engravable polymer film in the laminate piece with the reproductions, for example the polymer end layer 110. The data are engraved into the laminate piece in a laser engraving device.

[0083] Finally, the quality of the finished map 100 is checked in a fourteenth processing step in a quality assurance device as a system module. This includes, for example, camera systems, which, among other things, check the quality of the generated data reproductions.

[0084] The card copies checked for quality are finally issued from the production facility as finished identification cards or other document cards 100.

[0085] The above with reference to Fig. 2 The method for producing identity cards 100 and other document cards 100 described as an example can be carried out according to the invention in the Fig. 3shown schematic production plant 1000 according to the present invention. For this purpose, this plant is formed by plant modules 3100, 3200, 3300, 3400, 3500 and transport units 4100, 4200, 4300, 4400. A plant control unit 2000, for example a process computer with a memory unit, controls the plant modules and the transport units and receives data from the plant modules and transport units (each shown as an example for the data exchange between the plant control unit on the one hand and the first and second plant modules 3100, 3200 and the first and second transport units 4100, 4200; not shown for the other plant modules 3300, 3400, 3500 and transport units 4300, 4400).The transport units can be formed by translational conveyor systems, such as conveyor belts with branching options and transport gallows (translationally movable holding elements), or robots, such as lifting and swiveling robots, for example a SCARA robot, or a fast picker or a gantry crane.

[0086] The system modules 3100, 3200, 3300, 3400, and 3500 can be arranged in any desired arrangement relative to one another. However, it is advantageous if system modules intended for the execution of the same processing step and / or consecutive processing steps are arranged in close proximity to one another. Therefore, the system modules intended for the execution of the same processing step can be housed, for example, in a common production unit, which is realized by structural units in containers or container-like structures. Fig. 3For the system modules 3100, this is indicated by dashed lines for the first processing step by combining the same groups of system modules, for example in a containerized production unit. Similarly, the modules required for the execution of processing steps 11 and 12 ( Fig. 2 ) used system modules are housed in a common production unit, which are realized by construction units in containers or container-like structures, insofar as these system modules are to be used to process laminate pieces which, due to their format (for example ID-3) and their further purpose for inclusion in a passport, are to be provided with a passport flap 150. This combination is also in Fig. 3 indicated by dashed lines at the corresponding location for the system modules 3330, 3400.

[0087] Two system modules 3100 are provided for the execution of a first processing step. For example, in the case of the system 1000 for the production of ID cards 100, these can be a first and a second quality assurance device 3110, 3120. Of course, further system modules and transport units are located upstream of these system modules, which carry out the processing steps 1 to 6 from Fig. 2 These upstream plant modules and transport units are in Fig. 3 not shown.

[0088] According to this example, the system modules 3100 are used to carry out processing step 7. These quality assurance devices 3110, 3120 can be identical in order to provide a redundant system for this processing step in the event that one of these devices fails during the production process, so that the other quality assurance device can take over further operation alone. A combination of identical quality assurance devices can also be advantageous for reasons of capacity utilization of these system modules, for example, if more trimmed laminate pieces are fed to these modules in a given time unit than a single system module can process, so that the laminate pieces are each fed to one of the two quality assurance devices that is currently available for the inspection tasks, while the other is occupied with inspecting the laminate pieces.For example, one of the two quality assurance devices can be assigned to testing the quality of a trimmed laminate piece, so that a subsequent trimmed laminate piece is directed to the other quality assurance device. For this purpose, the system control unit 2000 uses the feedback from the system modules 3100, which acknowledge the arrival and completion of laminate pieces in the individual modules, to identify which of the two quality assurance devices is currently occupied. Accordingly, it issues control commands to an upstream transport unit (not shown) to transport the next laminate piece to the free quality assurance device. Furthermore, the system control unit transmits individual data of the laminate piece to be inspected to the processing quality assurance device so that it can check the respective quality criteria for this laminate piece.For example, if the laminate piece has the ID-3 format, it must be ensured that the trimming was carried out correctly in the preceding processing step 6. Likewise, the lamination result in processing step 5 must also be checked, taking into account, for example, the presence of a security thread and its exact position in the laminate. Likewise, the functionality of any RFID circuitry must be verified, and the data stored in the RFID chip must be compared with the target data to ensure that the circuitry intended for the respective laminate piece with a programmed RFID chip has been correctly assigned to this laminate piece.

[0089] If the quality assurance device 3100 determines that an inspected laminate piece does not meet the quality requirements, it is removed from the production process as a reject piece to a collection point 3101, indicated here by a wastepaper basket.

[0090] Downstream of the quality assurance devices 3100, a first transport unit 4100 is located, to which the inspected laminate pieces are transferred. This transport unit conveys the individual laminate pieces to one of three system modules 3200, which are formed by application devices 3210, 3220, and 3230 for hologram sections.

[0091] Processing step 10 is carried out in these application devices 3210, 3220, 3230. The application devices can differ in that they can process laminate pieces and hologram sections in different formats, such as laminate pieces in ID-1 format for ID cards 100 and laminate pieces in ID-3 format for document cards 100 to be bound into passports. If, for example, a laminate piece in ID-1 format is pending, the system control unit 2000 issues a control command to the first transport unit 4100 to transfer this laminate piece to the application device in which laminate pieces with this format are processed. For a laminate piece in ID-3 format, a corresponding control command for transfer to the other application device is issued in this example.As previously explained for the execution of the quality inspection, the system control unit also transmits individual data about the transferred laminate piece to the respective application device. Alternatively or additionally, the application devices can be identically constructed and each process the same laminate pieces. This type of redundancy has the advantage that this processing step can still be carried out even if, for example, one of the application devices fails. For example, the system control unit can detect from feedback from the failed application device that this device is no longer available. It will therefore then select a different application device for a laminate piece to be processed. Furthermore, the application devices can be started up depending on their current availability.If, for example, one of the two application devices is occupied with another piece of laminate when processing step 10 is carried out, a subsequent piece of laminate is fed to one of the other two application devices.

[0092] A second transport unit 4200 is located downstream of the application devices 3210, 3220, and 3230, to which the laminate pieces coated with the hologram sections are transferred. This transport unit conveys the individual laminate pieces to one of four system modules 3300, which are formed by format trimming devices 3310, 3320, 3330, and 3340.

[0093] Processing step 11 is carried out in these format trimming devices 3310, 3320, 3330, 3340. The trimming devices can differ, for example, in that they can process laminate pieces in different formats. Alternatively or additionally, the format trimming devices can be constructed identically and each process laminate pieces of the same type. For example, two format trimming devices can be designed to trim laminate pieces in ID-1 format and two format trimming devices can be designed to trim laminate pieces in ID-3 format. Such redundancy has the advantage, as explained above for the case of the quality assurance devices 3110, 3120 and application devices 3210, 3220, 3230, that this processing step can still be carried out even if, for example, one of the trimming devices fails.In addition, the format trimming devices can be approached depending on their current availability.

[0094] A third transport unit 4300, to which the trimmed laminate pieces are transferred, is located downstream of the format trimming devices 3310, 3320, 3330, 3340. This transport unit transports the individual trimmed laminate pieces to a system module 3400, which is formed by a device for attaching a tab 150 to the laminate piece (processing step 12). However, it can be provided that this third transport unit does not transport the laminate piece to this system module 3400, but rather to the fourth transport unit 4400 or directly to the system modules for the fifth processing step, because the card to be produced is an ID card 100 to which no registration tab is to be attached. In this case, the laminate piece is then transported directly to the system modules 3500 according to processing step 13, bypassing processing step 12.

[0095] Processing step 12 is carried out in the device 3400 for attaching the fitting tab 150. This device can be a hot-melt device, optionally equipped with an ultrasonic welding device.

[0096] Downstream of the device 3400 for applying the tab 150 is a fourth transport unit 4400, to which the laminate pieces (with or without a tab) are transferred. By means of the fourth transport unit, the laminate pieces are transferred to one of two downstream system modules 3500, which are formed by laser engraving devices 3510, 3520.

[0097] Processing step 13 is performed in the laser engraving devices 3510, 3520. The laser engraving devices can be identically constructed, each of which engraves reproductions of individualizing data into the laminate pieces. Such redundancy has the advantage, as explained above for the case of the quality assurance devices 3110, 3120, application devices 3210, 3220, 3230, and format trimming devices 3310, 3320, 3330, 3340, that this processing step can still be performed even if, for example, one of the laser engraving devices fails. Furthermore, the laser engraving devices can be started up depending on their current availability.

[0098] The laser engraving devices 3510 and 3520 are followed by another transport unit, from which the laminate pieces are transported to further quality assurance devices. These transport units and the further downstream system modules are Fig. 3 not shown.

[0099] The system control unit 2000 receives data from the system modules 3100, 3200, 3300, 3400, 3500 and transport units 4100, 4200, 4300, 4400, which indicate the respective location of an identified piece of raw material and its quality status (properties). Furthermore, the system control unit also receives data from the system modules and transport units regarding their operating status (occupancy by a piece of raw material, malfunctions, pending maintenance, and the like). A memory unit of the system control unit also stores which processing steps and which processing variants of the processing steps are being executed by the system modules.Based on this data, the system control unit can guide the raw material pieces to the system modules in a targeted manner by, on the one hand, determining the subsequent processing step to be performed for a specific raw material piece based on the respective processing scheme and assigning the raw material piece to one of the corresponding system modules. From these system modules, one is then selected according to the specifications of the card 100 to be produced that can perform the appropriate processing step. In the case of several identical system modules for this processing step and processing variant, the one that is not occupied by other raw material pieces currently being processed is selected. In addition, the system control unit transmits the individual data required for processing a specific raw material piece to the processing system module so that it has all the information and data it needs for processing. List of reference symbols:

[0100] 100Value or security document, ID card, document card 110First polymer end layer 120Individualized film section 130Polymer layer stack piece 131Polymer carrier layer 132Compensation layer 133Opaque cover layer 135Chip 140Second polymer end layer 150Document card flap 1000Production system 2000System control unit 3100System modules for the first processing step 3101Collection point for rejects 3110First system module for the first processing step, first quality assurance device 3120Second system module for the first processing step, second quality assurance device 3200System modules for the second processing step 3210First system module for the second processing step, first application device 3220Second system module for the second processing step, second Application device 3230third system module for the second processing step,Third application device 3300 System modules for the third processing step 3310 First system module for the third processing step, first format trimming device 3320 Second system module for the third processing step, second format trimming device 3330 Third system module for the third processing step, third format trimming device 3340 Fourth system module for the third processing step, fourth format trimming device 3400 System module for the fourth processing step, device for attaching a (fitting) tab 3500 System modules for the fifth processing step 3510 First system module for the fifth processing step, first quality assurance device 3520 Second system module for the fifth processing step, second quality assurance device 4100 First transport unit 4200 Second transport unit 4300 Third transport unit 4400 Fourth transport unit,

Claims

1. A system (1000) for producing value and security documents (100) from pieces of primary material in at least two processing steps of a processing scheme, said system being formed by: (a) system modules (3100, 3200, 3300, 3400, 3500) configured to execute the at least two processing steps; (b) at least one transport unit (4100, 4200, 4300, 4400), connecting the system modules (3x00), for the pieces of primary material intended for producing the value and security documents (100); and (c) a system control unit (2000) configured to control the at least one transport unit (4x00), wherein at least two system modules (3x00) are provided for executing each of the at least two processing steps; wherein all system modules (3x00) configured to execute a second processing step are connected by means of the at least one transport unit (4x00) to system modules (3x00) configured to execute a preceding first processing step; and wherein the at least one transport unit (4x00) is controllable using the system control unit (2000), so that the pieces of primary material are each feedable to one of a plurality of system modules (3x00) configured to execute a processing step, and wherein at least two system modules (3x00) configured to execute one of the at least two processing steps are each configured to execute a processing step variant to produce one of a plurality of variants of the value or security documents (100).

2. The system (1000) according to claim 1, characterised in that the system control unit (2000) is configured to detect the identity of a piece of primary material located in a system module (3x00) or a transport unit (4x00) and to control the feed of this piece of primary material to a system module (3x00) in dependence on the identity of this piece of primary material.

3. The system (1000) according to any one of the preceding claims, characterised in that the system control unit (2000) is configured to detect and to process data relating to the quality according to at least one quality criterion of a piece of primary material which has been processed in a system module (3x00) configured to execute an executed processing step, and to control the at least one transport unit (4x00) to feed this piece of primary material to a system module (3x00) configured to execute a processing step which is to be executed subsequently, in dependence on the determined quality in accordance with this quality criterion.

4. The system (1000) according to any one of the preceding claims, characterised in that the system control unit (2000) is configured to detect and process data relating to the operating state of at least one of a plurality of system modules (3x00) configured to execute a processing step and to control the at least one transport unit (4x00) for feeding the pieces of primary material to the system modules (3x00) configured to execute this processing step, in dependence on the determined operating state.

5. The system (1000) according to any one of the preceding claims, characterised in that the system modules (3x00) each have devices for transferring the pieces of primary material from and to the at least one transport unit (4x00), wherein the levels of the devices for transfer are configured to be of the same height.

6. The system (1000) according to any one of the preceding claims, characterised in that in that at least one of the system modules (3x00) is formed by a printing device or a laying device for collating pieces of primary material or a laminating device or an edge trimming device or a device for determining the quality of the pieces of primary material produced during lamination in the form of polymer laminates or a hologram production device or a hologram application device or a format trimming device or a device for attaching a tab to the pieces of primary material or a laser engraving device or by a device for detecting the quality of the finished value or security document.

7. The system (1000) according to any one of the preceding claims, characterised in that the system (1000) has at least first system modules (3100), which are configured to execute a first processing step, second system modules (3200), which are configured to execute a second processing step, and third system modules (3300), which are configured to execute a third processing step, and in that all second system modules (3200) are connected to all first system modules (3100) by means of at least one first transport unit (4100), and in that all third system modules (3300) are connected to all second system modules (3200) by means of at least one second transport unit (4200) different from the at least one first transport unit (4100), wherein the at least one first transport unit (4100) is configured exclusively for transferring the pieces of primary material from the first system modules (3100) to the second system modules (3200) and the at least one second transport unit (4200) is configured exclusively for transferring the pieces of primary material from the second system modules (3200) to the third system modules (3300).

8. A method for producing value and security documents (100) from pieces of primary material in at least two processing steps of a processing scheme with system modules (3100, 3200, 3300, 3400, 3500) configured to execute the at least two processing steps and with at least one transport unit (4100, 4200, 4300, 4400) connecting the system modules (3x00), said method comprising the following method steps: (i) providing the pieces of primary material intended for producing the security documents (100); (ii) controlling the at least one transport unit (4100, 4200, 4300, 4400) by means of a system control unit (2000) configured to control the at least one transport unit (4x00) for feeding a piece of primary material to a selected one of at least two system modules (3x00) configured to execute a processing step to be executed; (iii) feeding the piece of primary material to the selected system module (3x00); (iv) executing the processing step in the selected system module (3x00) by changing at least one property of the piece of primary material; and (v) executing further processing steps of the processing scheme according to the above method steps (ii), (iii) and (iv), wherein the method further comprises: controlling the at least one transport unit (4x00) by the system control unit (2000), so that the pieces of primary material are fed to one of the system modules (3x00) configured to execute this processing step variant for producing one of a plurality of variants of the value or security documents (100), in dependence on the execution of a processing step variant to be selected.

9. The method according to claim 8, characterised in that the method further comprises: detecting the identity of a piece of primary material located in a system module (3x00) or a transport unit (4x00) with the system control unit (2000) and controlling the feed of this piece of primary material to a system module (3x00) in dependence on the identity of this piece of primary material.

10. The method according to any one of claims 8 or 9, characterised in that the method further comprises: the detection and processing of data relating to the quality according to at least one quality criterion of a piece of primary material which has been processed in a system module (3x00) configured to execute an executed processing step, by the system control unit (2000), and controlling the at least one transport unit (4x00) for feeding this piece of primary material to a system module (3x00) configured to execute a processing step to be executed subsequently, in dependence on the quality of the piece of primary material.

11. The method according to any one of claims 8 to 10, characterised in that the method further comprises: the detection and processing of data relating to the operating state of at least one of a plurality of system modules (3x00) configured to execute a processing step by the system control unit (2000) and control of the at least one transport unit (4x00) for feeding the pieces of primary material to the system modules (3x00) configured to execute this processing step in dependence on the determined operating state.

12. The method according to any one of claims 8 to 11, characterised in that the processing scheme comprises at least one optional processing step to be executed only for a specific group of value or security documents (100).

13. The method according to any one of claims 8 to 12, characterised in that the changing of at least one property of the pieces of primary material according to method step (iv) further comprises printing the pieces of primary material and / or collating the pieces of primary material and / or laminating the pieces of primary material and / or edge-trimming the pieces of primary material and / or determining the quality of the laminated and edge-trimmed pieces of primary material and / or generating a hologram and / or applying the hologram to the pieces of primary material and / or format-trimming the pieces of primary material and / or attaching a tab to the pieces of primary material and / or laser-engraving the pieces of primary material.

14. The method according to any one of claims 8 to 13, characterised in that method step (iii) comprises feeding the piece of primary material to a first selected system module (3100), and in that method step (v) comprises the following further method steps: (v-1)controlling at least one first transport unit (4100) exclusively assigned to the first system modules (3100) and second system modules (3200) by means of the system control unit (2000) for feeding the piece of primary material to a second selected system module (3200) configured for executing a second processing step;(v-2)feeding the piece of primary material to the second selected system module (3200);(v-3)carrying out the second processing step in the second selected system module (3200) by changing at least one property of the piece of primary material;(v-4)controlling at least one second transport unit (4200) assigned exclusively to the second system modules (3200) and third system modules (3300) bymeans of the system control unit (2000) for feeding the piece of primary material to a third selected system module (3300) configured for executing a third processing step;(v-5)feeding the piece of primary material to the third selected system module (3300);(v-6)executing the third processing step in the third selected system module (3300) by modifying at least one property of the piece of primary material.

15. A method for producing an assembly of a plurality of different value and security documents according to individual processing schemes by carrying out the method according to any one of claims 8 to 14.